CN1186587A - 细长柔性电热器及其制造方法 - Google Patents

细长柔性电热器及其制造方法 Download PDF

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CN1186587A
CN1186587A CN96194308A CN96194308A CN1186587A CN 1186587 A CN1186587 A CN 1186587A CN 96194308 A CN96194308 A CN 96194308A CN 96194308 A CN96194308 A CN 96194308A CN 1186587 A CN1186587 A CN 1186587A
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resistive element
insulating barrier
electrical heater
elongated flexible
flexible electrical
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根纳季·波尔菲列耶维奇·格兰先科夫
彼得·阿列克谢耶维奇·科列涅夫
伊戈尔·阿纳托利耶维奇·科兹洛夫
弗拉基米尔·阿尔卡季耶维奇·维云科夫
安德烈·鲍里索维奇·科卡琴科
列昂尼德·古尔维奇·舒舍林
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Russia International Inc
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Russia International Inc
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Priority claimed from RU95108156/07A external-priority patent/RU2072116C1/ru
Priority claimed from RU95108282/07A external-priority patent/RU2072117C1/ru
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Publication of CN1186587A publication Critical patent/CN1186587A/zh
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    • H—ELECTRICITY
    • H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05B—ELECTRIC HEATING; ELECTRIC LIGHT SOURCES NOT OTHERWISE PROVIDED FOR; CIRCUIT ARRANGEMENTS FOR ELECTRIC LIGHT SOURCES, IN GENERAL
    • H05B3/00—Ohmic-resistance heating
    • H05B3/02—Details
    • H05B3/06—Heater elements structurally combined with coupling elements or holders
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R11/00—Individual connecting elements providing two or more spaced connecting locations for conductive members which are, or may be, thereby interconnected, e.g. end pieces for wires or cables supported by the wire or cable and having means for facilitating electrical connection to some other wire, terminal, or conductive member, blocks of binding posts
    • H01R11/11—End pieces or tapping pieces for wires, supported by the wire and for facilitating electrical connection to some other wire, terminal or conductive member
    • H01R11/12—End pieces terminating in an eye, hook, or fork
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R4/00—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation
    • H01R4/10—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation effected solely by twisting, wrapping, bending, crimping, or other permanent deformation
    • H01R4/18—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation effected solely by twisting, wrapping, bending, crimping, or other permanent deformation by crimping
    • H01R4/183—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation effected solely by twisting, wrapping, bending, crimping, or other permanent deformation by crimping for cylindrical elongated bodies, e.g. cables having circular cross-section
    • H01R4/184—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation effected solely by twisting, wrapping, bending, crimping, or other permanent deformation by crimping for cylindrical elongated bodies, e.g. cables having circular cross-section comprising a U-shaped wire-receiving portion
    • H01R4/185—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation effected solely by twisting, wrapping, bending, crimping, or other permanent deformation by crimping for cylindrical elongated bodies, e.g. cables having circular cross-section comprising a U-shaped wire-receiving portion combined with a U-shaped insulation-receiving portion
    • H—ELECTRICITY
    • H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05B—ELECTRIC HEATING; ELECTRIC LIGHT SOURCES NOT OTHERWISE PROVIDED FOR; CIRCUIT ARRANGEMENTS FOR ELECTRIC LIGHT SOURCES, IN GENERAL
    • H05B3/00—Ohmic-resistance heating
    • H05B3/40—Heating elements having the shape of rods or tubes
    • H05B3/54—Heating elements having the shape of rods or tubes flexible
    • H05B3/56—Heating cables
    • H—ELECTRICITY
    • H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05B—ELECTRIC HEATING; ELECTRIC LIGHT SOURCES NOT OTHERWISE PROVIDED FOR; CIRCUIT ARRANGEMENTS FOR ELECTRIC LIGHT SOURCES, IN GENERAL
    • H05B2203/00—Aspects relating to Ohmic resistive heating covered by group H05B3/00
    • H05B2203/016—Heaters using particular connecting means

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  • Resistance Heating (AREA)

Abstract

本发明涉及具有碳纤维电阻元件的柔性电热件而可独立用于加热暖房、家用和工业器件以及用作加热器之类其他装置中的部件。本发明还涉及制造该柔性电热件的方法。该电热器包括做成碳纤维束捆的电阻元件、用导热材料制成的绕组或辫子状第一绝缘层、用聚合材料制成的第二绝缘层、其上有三对突齿的供电件。三对突齿之一把电阻元件的绝缘层剥去的端部紧固在该接头与一段第一绝缘层之间,第二对突齿压接第二绝缘层,第三对突齿紧固绝缘管。本发明可提高单位表面发热量、该电热器的可靠性并使其制造更简单、高效。

Description

细长柔性电热器及其制造方法
发明领域
本发明的细长柔性电热器涉及加热装置，特别涉及具有碳纤维电阻元件的柔性电热件。
细长柔性电热器可独立用作电热器而加热暖房、家用和工业器件以及用作加热器之类其他装置中的部件。
发明背景
把金属合金用作电阻元件的细长电热器是公知的。现有技术(1)描述了一种具有电绝缘芯线的细长电热器。金属电阻元件卷绕在所述芯线上，而所述金属电阻元件上有一绝缘层。
该电热器的主要缺点是一层绝缘层的可靠性低。弯曲时和经长期使用，金属电阻元件会戳穿绝缘层。
现有技术(2)提出一种包括一根或多根电阻元件芯线的细长电热器，芯线外部涂有两层绝缘层。外绝缘层用防止电热器发生弯曲的非柔性绝缘材料制成。这是一个重大缺点，因为该电热器的应用范围受到很大限制，它无法用于各种尺寸的加热对象上。
与本发明最接近、从而作为本发明原型的现有技术(3)描述了一种多根由碳纤维丝做成的束的电阻件和两层绝缘层的细长柔性电热器。由弹性导热、电绝缘聚合材料制成的第一层绝缘物融合在电阻元件的碳丝之间而固定这些碳丝。第二层绝缘用相同材料做成覆盖层。供电接头连接到电阻元件的自由端上。然后在其上套一绝缘管。这一电热器的缺点是绝缘不可靠，因为在用弹性绝缘材料融合和固定电阻元件的过程中，涂层厚度在线束周长和长度上会有很大差别，从而在某些部位根本不绝缘。在这些部位上只有覆盖层起绝缘作用。如该绝缘损坏、特别是在由于与发热电阻元件发生接触而损坏时，该电热器就会短路而烧坏。该电热器的另一个缺点是用接头直接把电阻元件连接到供电件上而不可靠，因为受压时脆性碳纤维与金属之间会接触过紧。此时一部分碳纤维会损坏，从而接触电阻增加、过热而烧坏触点。在该电热器受到机械应力(拉伸应力)时，该应力会经接头传到电阻元件上，从而由于与碳纤维的机械连接强度低而损坏电热器。因此须克服上述缺点而实现工作温度范围更宽、单位表面发热量增加、细长柔性电热器的可靠性提高、制造方法更简单、有效的技术结果。
本发明概述
为解决上述问题而实现细长柔性电热器的上述技术结果，可把细长柔性电热器做成为具有两层绝缘层的碳丝线束捆(bundle)，第一层绝缘层用纤维材料做成绕组或辫子状，第二绝缘层为聚合物涂层，电阻元件的两端除去绝缘后用第一对突齿固定在具有三对突齿的接头与第一绝缘层的一段之间，第二对突齿压接第二绝缘层，第三对突齿紧固绝缘管。
在该细长柔性电热器中，电阻元件以螺旋形卷绕在一由纤维材料制成的实心芯线上而做成具有焦碳涂层的玻璃纤维线束。电阻元件卷绕成间距大于或等于5mm。电阻元件的长度上分布有低电阻涂层段而形成高电阻分流段，其中，低电阻段的电阻为高电阻段的电阻的1/100或1/200。
把电阻元件做成束捆提高了可靠性而防止碳丝在以很小半径弯曲时发生断裂。电绝缘层做成绕组或辫子状提高了可靠性，从而即使在以很小半径弯曲时也可防止发热电阻元件戳穿绝缘层或接触到第二聚合物绝缘层。结果单位发热量增加，电热器的工作温度范围更宽。
此外，由于第一绝缘层用纤维制成，从而确保电热器的寿命；并且由于在把碳纤维弯曲地连接到接头上从而把电阻元件连接到第一绝缘层上后用接头的突齿压紧，从而防止碳纤维遭到损坏；因此提高了该电热器的可靠性。这样，接头的突齿不与电阻元件直接接触。压紧力经一柔软层施加(到纤维绝缘层中的电阻元件线束上)。这样可确保以低接触电阻实现可靠的电连接。为了提高接头与电绝缘层的机械连接的可靠性，接头上设置有紧压到其外层绝缘层剥去的第一绝缘层上的第二对突齿。而且端部设置有紧固聚合物绝缘涂层或者绝缘管的第三对突齿。
为了获得上述技术结果，在细长柔性电热器的所述制造方法中，把两层绝缘层加到做成碳纤维束的电阻元件的中间产物上，电阻元件端部的绝缘层剥去，把供电件放置到所述端部上后电阻元件的连接部与绝缘管的供电件紧贴，在卷绕碳纤维丝时把电阻元件的中间产物做成束捆，在施加第一绝缘层的过程中调节电阻元件的碳纤维丝的拉力而使其保持成束捆状，从电阻元件端部剥去的第二层绝缘层的长度比剥去的第一绝缘层的长度长约电阻元件露出的长度，然后电阻元件的该露出部分弯曲而紧固在第一绝缘层与其上有三对突齿的供电件接头之间，这些突齿压接到该电热器的所有部件上。
在制作电阻元件的中间产物的过程中，碳纤维丝以螺旋形卷绕成束捆，而在形成绕组和辫子状第一绝缘层时，导热纤维材料调节碳纤维丝的拉力而使其保持束捆状。这是一种自动过程，无需进行调节。不释放有害化合物。此外，无需为了提高传热性在聚合材料中添加金属添加剂。第二绝缘层也是自动挤压成形。电阻件不再是融合在绝缘层中。在从电阻元件端部剥去绝缘层时，所剥去的第二绝缘层的长度比第一绝缘层的剥去长度多出约为电阻元件露出部分的长度。由于电阻件不再是融合在绝缘层中，因此制造过程简化，质量高而不会损坏电阻元件。
把电阻元件弯曲后紧固在第一绝缘层与接头之间简化了电阻元件的压接，因为在压接后无需进行调节。
对专利和期刊进行检索的结果表明本申请满足专利的“新颖性”要求。
由于对细长柔性电热器存在需求，而它可用公知方法、公知组件和公知材料制成，因此本发明满足“实用性”要求。由于本发明细长柔性电热器的可靠性、工作温度范围和单位表面发热量提高，因此满足“创造性”要求。
附图的简要说明
图1为电热器的工作部分，其中，1为由纤维材料制成的第一绝缘层，2为由聚合材料制成的第二绝缘层，3为电阻元件。
图2简示出电阻元件与接头之间的连接，其中，4为接头，5为接头的一对突齿。
图3为把该电热器连接到接头上的一部件，其中，6为第二对突齿，7为第三对突齿。
该细长柔性电热器的制作方法如下：在多根(a cluster of)碳纤维丝卷绕而成的束捆上，编织或绕制绝缘材料丝，然后套上挤压成形的聚合物绝缘层(第二绝缘层)。在编织和绕制过程中控制丝的拉应力而保持束捆状。这样获得第一绝缘层的比编织(绕制)丝的厚度大两倍的均匀厚度。这样只需一个加工周期即可制成第一纤维和第二聚合物绝缘层。把所得到的半成品切出长度一定的一段段。把每一段两端的第一和第二绝缘层剥去。所剥去的第一绝缘层的长度约等于由接头的第一对突齿压接的长度。所剥去的第二绝缘层的长度约为第一绝缘层剥去长度的两倍。电阻元件露出部分弯曲180°后放到接头上用第一对突齿紧固。用一压机压接突齿，从而确保同时用第一对突齿压接弯曲的电阻元件与第一绝缘层、用第二对突齿压接第二绝缘层和用第三对突齿压接第二绝缘层或者绝缘管。
对本发明一实施例的说明
在一绞合架(TK-160I型)上用URAL N-22型的10根碳纤维丝绞合成一30-40转/米的束捆。在 SP-16型编织机上用线密度为200tex的16根硅丝编织在所述束捆上后送到ENS 45×25型挤压成形机。在所述挤压成形机中把PVC型第二绝缘层加到纤维绝缘层上。第一绝缘层的厚度为0.8mm，第二绝缘层的厚度为1.0mm。
把该半成品切割成长度为15m的一段段中间产品。剥去该中间产品两端的绝缘层。所剥去的第一绝缘层的长度为10mm，所剥去的第二绝缘层的长度为20mm。电阻线束的露出部分弯曲180°后放置到接头上而用第一对突齿紧固。在压机中压接各对突齿。
现有专利
1、DE 29 17 639，H05 B3/56，1982
2、EP 0 368 776，H05 B 3/56，1990
3、GB 1303917，H05 BB3/56，1973(与本发明最接近的现有技术)

Claims (6)

1、一种细长柔性电热器，包括：用多根碳纤维丝绕成束的电阻元件；两层绝缘层，第一绝缘层由导热材料制成，第二绝缘层由聚合物涂层制成；用作供电件的接头和；套在电阻元件与供电件的每个连接部上的绝缘管，其特征在于，电阻元件做成束捆状，第一绝缘层做成纤维材料的绕组或辫子，供电件上有三对突齿，电阻元件的绝缘层剥去的端部用第一对突齿紧固在接头与一段第一绝缘层之间，第二对突齿压接第二绝缘层，第三对突齿紧固绝缘管。
2、按权利要求1所述的细长柔性电热器，其特征在于，电阻元件以螺旋形卷绕在一由纤维材料制成的实心芯线上。
3、按权利要求1所述的细长柔性电热器，其特征在于，电阻元件由具有焦碳涂层的玻璃纤维束捆构成。
4、按权利要求1所述的细长柔性电热器，其特征在于，电阻元件绕制成间距大于或等于5mm。
5、按权利要求1所述的细长柔性电热器，其特征在于，电阻元件的长度上分布有低电阻涂层段而形成高电阻分流段，其中，低电阻段的电阻为高电阻段的电阻的1/100或1/200。
6、一种制造细长柔性电热器的方法，其中，把两层电绝缘层加到做成成束碳纤维丝的电阻元件的中间产物上，剥去电阻元件端部的绝缘层剥去，把供电件放置到所述端部上后电阻元件的连接部与绝缘管的供电件紧贴，其特征在于，在卷绕碳纤维丝时把电阻元件的中间产物做成束捆，在施加第一绝缘层的过程中调节电阻元件的碳纤维丝的拉力而使其保持束捆状，从电阻元件端部剥去的第二层绝缘层的长度比剥去的第一层绝缘层的长度长约电阻元件露出的长度，然后电阻元件的该露出部分弯曲而紧固在第一绝缘层与其上有三对突齿的供电件接头之间，这些突齿压接到该电热器的所有部件上。
CN96194308A 1995-05-29 1996-05-28 细长柔性电热器及其制造方法 Pending CN1186587A (zh)

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RU95108156 1995-05-29
RU95108156/07A RU2072116C1 (ru) 1995-05-29 1995-05-29 Электронагревательный кабель
RU95108282 1995-06-01
RU95108282/07A RU2072117C1 (ru) 1995-06-01 1995-06-01 Длинномерный гибкий электронагреватель и способ его изготовления

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WO1996039006A1 (fr) 1996-12-05
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AU5848796A (en) 1996-12-18
AU711363B2 (en) 1999-10-14

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